EP2457679A1 - Method of simulating a welding process - Google Patents

Abstract

The device (1) comprises a computer (2) having an input device (11) and an output device (6), a welding torch, a magnetic position monitoring device (5) having a transmitter and sensors, a retaining device for a workpiece used for the simulation, and a visualization device for generating two- or three-dimensional image on the output device. The retaining device has a recess, into which the workpiece is inserted. The transmitter of the position monitoring device is arranged below the recess at a small distance from the workpiece. The retaining device is designed as a small, portable box. The device (1) comprises a computer (2) having an input device (11) and an output device (6), a welding torch, a magnetic position monitoring device (5) having a transmitter and sensors, a retaining device for a workpiece used for the simulation, and a visualization device for generating two- or three-dimensional image on the output device. The retaining device has a recess, into which the workpiece is inserted. The transmitter of the position monitoring device is arranged below the recess at a small distance from the workpiece. The retaining device is designed as a small, portable box to be placed on a table. The box and the workpiece is made of electrically and magnetically non-conducting plastic material. The transmitter is arranged below the workpiece at the central position of the retaining device, so that the distance of the transmitter to the sensor in the welding torch is minimized during simulating the welding process. The box is formed with the workpiece for the simulation of horizontal welding and vertical welding. The workpiece and the box are equipped with a radio frequency identification chip and a radio frequency identification laser. The marked areas for an entry over the welding torch are arranged at the box. The areas are formed as verification switching area, replication switching area, menu switching area and reverse switching area, so that the corresponding command is implemented to the computer during positioning and activating the welding torch. The welding torch is built up by a torch handle and a pipe elbow and has pipe connection for the computer. A sensor is arranged in the area of a torch tip for determining the position. A movably mounted pin is arranged at the torch tip for simulating a welding wire. A starting switch is arranged at the torch handle for activating the simulation of the welding process. A switching element is arranged at the torch handle for adjusting the predetermined welding parameters such as wire feed, voltage and current. A welding shield or a cap, at which the sensor is arranged, is connected with the position monitoring device and/or the computer. The control of the camera over the position monitoring device takes place for the visualization of the scene on an image screen. Polhemus-sensor is arranged at a welding helmet and/or at the cap and Polhemus-transmitter, over which the position of the camera is determined, is arranged in the workpiece. A case is provided for the arrangement of all components. Independent claims are included for: (1) a method for generating two-dimensional images on an output device over a visualization device for simulating a welding process; and (2) a method for controlling a simulated welding process.

Description

The invention relates to a method for controlling a simulated welding process by a user as described in the preamble of claim 1.

Different visual welding systems are already known. For example, a visual welding system is shown at www.simwelder.com, which is formed from a base element, a welding station and a workpiece element. In the base element, the computer unit for calculating the welding process and a screen for displaying the welding process is arranged. Furthermore, a welding torch is connected to the base element via a hose package with which a visual welding can be carried out without contact on a workpiece used for the simulation in the welding position. For this purpose, the welding stand has a receiving device in the form of a U-shaped frame with a fastening device into which different sliding elements with workpieces serving for simulation can be inserted. Thus, the sliding elements with the different workpieces on the fastening device can always be attached in the same position on the weld. The position detection of the welding torch in relation to the workpiece via a magnetic position monitoring system, in particular with a so-called Polhemus tracker.

A major disadvantage of this visual welding system is that it takes up a very large amount of space. If this visual welding system is constructed, then after the installation of the individual systems, in particular of the base element and the welding level, an exact calibration of the two elements must first be carried out with each other, after which the two elements, in particular the base element and the welding level, must not be displaced, otherwise a new calibration must be performed.

Another disadvantage is that only one VR (Virtual Reality) goggle can be used in this known system. Since not all people can wear VR glasses for different reasons (ametropia, wearers of glasses) are by a System that relies only on visualization with the VR glasses, excluding certain users.

The object of the present invention is to provide an abovementioned method for the simulation of a welding process with which the process can be simulated as realistically as possible and operated as simply as possible. Disadvantages of known devices and methods should be avoided or reduced.

The object of the invention is achieved by a method according to claim 1, wherein at least a defined region of the designed as a small, portable box for placement on a table holding device is formed as an input module with stored functions, and by contactless positioning of the welding torch in the vicinity of this at least a defined range or by touching the at least one defined area and by activating a switching element on the welding torch and by determining the position of the welding torch on the sensor and the encoder in the box, the stored functions are selected and activated. The advantage here is that through the use of the welding torch as a control, the user does not constantly put the torch from the hand to make certain inputs, whereby the user-friendliness of the system is significantly increased. The selection of the defined areas is either contactless over the welding torch by determining the position of the welding torch, the user needs to drive to select the area only with the welding torch in the vicinity of this area or by touching the defined area with the welding torch.

Advantageously, the at least one defined area is defined by the software in terms of the position on a box and preferably marked by a simple sticker on the box. As a result, the user can make further inputs or call commands in a simple manner after performing a welding simulation with the welding torch.

The touching of the defined area can be performed with a stylus for simulating a welding wire, whereby a switching element coupled to the stylus is activated and the function stored for this defined area is selected and activated. This allows the user to call up functions by simply pressing the area.

Also advantageous are measures according to which the stored function for the defined area are preferably selected for the start of the welding simulation or repetition of the welding simulation, etc., since the user can immediately start the next welding simulation by activating these areas.

Fig. 1

eine schaubildliche Darstellung einer in einem Koffer angeordneten Vorrichtung für die Simulation eines Schweißprozesses;

Fig. 2

die Vorrichtung für die Simulation eines Schweißprozesses im aufgebauten Zustand;

Fig.3

einen Schweißbrenner mit integrierten Sensoren für die Simulationsvorrichtung, in vereinfachter, schematischer Darstellung;

Fig.4

eine Haltevorrichtung zum Einlegen eines Werkstückes für die Simulationsvorrichtung, in vereinfachter, schematischer Darstellung;

Fig.5

ein Werkstück zum Einlegen in die Haltevorrichtung für die Simulationsvorrichtung zum Trainieren einer Kehlnaht, in vereinfachter, schematischer Darstellung;

Fig.6

ein weiteres Werkstück zum Trainieren einer Kehlnaht mit ausgebildeter ersten Schweißraupe;

Fig.7

ein anderes Werkstück zum Einlegen in die Haltevorrichtung zum Trainieren einer Stumpfnaht, in vereinfachter, schematischer Darstellung;

Fig.8

das Werkstück gemäß Fig.7 in umgedrehter Position mit ausgebildeter ersten Schweißraupe;

Fig.9

eine schaubildliche Darstellung für die Anzeige im statischen Zustand der Visualisierungsvorrichtung;

Fig. 10

eine schaubildliche Darstellung für die Anzeige im dyna- Fig. 11 mischen Zustand der Visualisierungsvorrichtung; eine schaubildliche Darstellung zur automatischen Erkennung der Händigkeit eines Benutzers am Beispiel eines Linkshänders bei der Verwendung eines Werkstücks zum Training einer Kehlnaht;

Fig. 12

eine schaubildliche Darstellung zur automatischen Erkennung der Händigkeit eines Benutzers am Beispiel eines Rechtshänders bei Verwendung eines Werkstückes zum Training einer Kehlnaht;

Fig. 13

eine Haltevorrichtung mit gekennzeichneten, definierten Bereichen zur Auswahl mit dem Schweißbrenner, in vereinfachter, schematischer Darstellung; und

Fig. 14

einen Schweißbrenner mit eingebauter Lichtquelle zur Simulierung eines Lichtbogens, in vereinfachter, schematischer Darstellung.

The present invention will be explained in more detail with reference to the accompanying schematic drawings. Show:

Fig. 1

a perspective view of a device arranged in a suitcase for the simulation of a welding process;

Fig. 2

the device for the simulation of a welding process in the established state;

Figure 3

a welding torch with integrated sensors for the simulation device, in a simplified, schematic representation;

Figure 4

a holding device for inserting a workpiece for the simulation device, in a simplified, schematic representation;

Figure 5

a workpiece for insertion into the holding device for the simulation device for training a fillet weld, in a simplified, schematic representation;

Figure 6

another workpiece for training a fillet weld with trained first weld bead;

Figure 7

another workpiece for insertion into the holding device for training a butt seam, in a simplified, schematic representation;

Figure 8

the workpiece according to Figure 7 in inverted position with trained first weld bead;

Figure 9

a perspective view of the display in the static state of the visualization device;

Fig. 10

a diagrammatic representation for the display in the dyna- Fig. 11 mix state of the visualization device; a perspective view of the automatic detection of the handedness of a user using the example of a left-handed person in the use of a workpiece for training a fillet weld;

Fig. 12

a perspective view of the automatic detection of the handedness of a user using the example of a right-hander when using a workpiece for training a fillet weld;

Fig. 13

a holding device with marked, defined areas for selection with the welding torch, in a simplified, schematic representation; and

Fig. 14

a torch with built-in light source for simulating an arc, in a simplified, schematic representation.

In the FIGS. 1 to 12 a device 1 for simulating a welding process is shown. Basically, it should be mentioned that in such a device 1, no actual welding process is performed, but that simulated via a software running on a computer 2, a welding process and is displayed virtually. In this case, a welding process can be trained by a user via a standard welding torch 3, which has been correspondingly rebuilt for such an application, ie, the guidance of the welding torch 3 in relation to a workpiece 4 can be practiced. Such simulation or training systems have the advantage that the user can practice a welding process as often as desired, without consuming corresponding additional material for the welding process and at the same time need no workpieces or objects, which would then have to be eliminated as a committee. Thus, for example, a welder can be trained on a new welding process, or it can be easier for new users to easily teach welding before they weld on the actual workpieces or objects.

Essential in such systems is the position determination of the individual components in real time to each other. The position of the welding torch 3 to the workpiece 4 and the position of the eyes The user, ie the viewing angle, should be recorded, evaluated and displayed as far as possible in real time. In the described embodiment, for this purpose, a magnetic position monitoring device 5 is used, which are formed for example of a prior art Polhemus tracker, Polhemus encoder, and Polhemus sensors, via which the positions, distances and velocities of the components are detected and then from a software running on a computer 2 into a virtual image with the associated welding conditions, such as the arc, the formed weld bead, etc., are converted and displayed either on a display device 6, in particular a commercial screen 7, or a 3D glasses ,

The solution shown is a compact, lightweight, and portable structure that is easy to handle, portable, and portable by a user without the need for specialized knowledge. In this case, all the components required in a commercially available case 8, as in Fig. 1 can be integrated. How out Fig. 2 can be seen, corresponding inserts 9 or elements are arranged in the case 8, in which the individual components are positioned. The components can be removed, set up and used by the user. The user can stow all components in the case 8 and easily make a change of location without additional people are needed. The device 1 can be easily built to save space on a table 10 or a workplace. Thus, it is achieved that, especially for new to-be-trained welders, they can take the case 8 home, for example, and carry out corresponding sweat exercises there.

The individual components of the device 1 for the simulation of a welding process consist of a computer 2 with an input device 11, in particular a keyboard 12 and / or a mouse, and an output device 6, a welding torch 3, a magnetic position monitoring device 5 with at least one encoder 13 and a plurality of sensors 14, a holding device 15 for a simulated workpiece 4 and a visualization device 16 or a 3D glasses for generating a two- or three-dimensional image on the output device 6. For clarity, the connecting lines between the components were not shown. In order to achieve a simple construction, the connection plugs for the connection lines have been designed in such a way that there is always only one pair of connecting plugs, so that the user can not make any incorrect connections during installation.

Preferably, however, the components are already interconnected so that they only need to be removed from the case 8. Only it is necessary for the user that a power supply must be made with the case 8 in order to supply the individual components with energy. For this purpose, a connection can be provided on the case 8, to which the user can connect a conventional power connection cable 17. In case 8, a supply system (not shown) is arranged, which is connected to all components, so that they can be supplied simultaneously with electrical energy. The user only has to connect the case 8 to a socket with a cable in order to supply all components with energy.

Since the use of magnetic position monitoring devices electrically and magnetically conductive materials can cause interference, the case 8 is preferably made of an electrically and magnetically non-conductive material, such as plastic. As a result, the case 8 can be integrated into the structure without causing interference from the case 8. The case 8 may, for example, guide rails, brackets, etc., have, in which the individual components can be attached. For example, it would be possible to attach the holding device 15 for the workpiece 4 to the case 8.

Preferably, in the construction of the device 1, the holding device 15 together with the associated workpieces 4, the welding torch 3 and the visualization device 16 are removed from the case 8 and placed on a workstation or table 10, whereas the other components, such as the computer 2 and the position monitoring device 5, preferably in the case 8 remain. The necessary line connections (not shown) between the components are already present so no additional connections need to be made by the user. For this purpose, the computer 2 with the input device 11, in particular keyboard 12, and the output device 6, in particular screen 7, with the welding torch 3, the magnetic position monitoring device 5, to which at least one encoder 13 and a plurality of sensors 14 is connected, and the visualization device 16 connected. The encoder 13 is positioned on the holding device 15, in particular in the interior of the holding device 15, for the workpiece 4 serving for the simulation and at least one sensor 14 at least on the visualization device 16 and the welding torch 3. In the illustrated embodiment, a single encoder 13 and a plurality of sensors 14 are used, which are integrated in the individual components and connected to the magnetic position monitoring device 5, are used. By such a configuration, in which all components for a simulation device 1 or virtual welding device can be stowed in a portable case 8 and the user only appropriate component from the case 8 must be removed in the construction, a high level of user-friendliness is achieved because the user no longer need to make cabling.

For the simulation of a welding process, a so-called simulated or simulation workpiece 4 is needed. At this workpiece 4, no actual welding operation is performed, but the workpiece 4 is only for guidance to the leadership of the welding torch 3. For this purpose, the holding device 15 has been created, which is placed in a simple form on a workstation or table 10 and in which the workpiece 4 is used. The holding device 15 is designed such that it can be oriented depending on the type of weld to be practiced, ie horizontal or vertical welding. The holding device 15 can be easily rotated and it is still a position detection without recalibration possible, with an automatic detection of the situation is performed due to the position of the welding torch 3 and rotated the image on the display device 6 accordingly becomes. Thus, with a workpiece 4, at least two welding operations, namely a horizontal and a vertical welding operation, be practiced by the holding device 15 is simply rotated, that is placed on the face, and the user with the welding torch 3 then the workpiece 4 moves accordingly.

So that a plurality of different types of welding processes can be trained, 15 different workpieces 4 can be used in the holding device, which in the FIGS. 5 to 8 are shown. For this purpose, the holding device 15 has a recess 18 into which a wide variety of workpieces 4 can be inserted. Below the recess 18 of the holding device 15, the encoder 13 of the position monitoring device 5 is arranged at the smallest possible distance from the workpiece 4. Preferably, the holding device 15 is designed in the form of a small, portable box 19 for placement on a table 10. The box 19 and the insertable workpiece 4 are in turn made of an electrically and magnetically non-conductive material, in particular plastic, so that no interference from these components can be caused in the position determination. It is important that the central position of the encoder 13 in the holding device 15 below the workpiece 4 a minimum distance to the sensor 14 in the welding torch 3 in a simulated welding is present and thus a very accurate position detection can be performed. Of course, an encoder 13 can be arranged on each workpiece 4 and this encoder 13 automatically contacted when inserting the workpiece 4 in the box 19 and connected to the position monitoring device 5. In the arrangement of the sensors 14, it is essential that they are positioned as close as possible to the encoder 13. For example, a sensor 14 in the welding torch 3 is preferably positioned in a gas nozzle 20, since the gas nozzle 20 forms the end region of the welding torch 3 and is brought very close to the workpiece 4 in a simulated welding process, as is known Fig. 3 is apparent. Thus, a very short distance between the encoder 13 below the workpiece 4 and the recess 18 and the zoomed over the gas nozzle 20 sensor 14 is given in the welding torch 3, so that a very accurate evaluation of the position of the welding torch 3 in Reference to the workpiece 4 is made possible. Furthermore, it is achieved by the fixed arrangement of the encoder 13 in the holding device 15 below the workpiece 4 and the recess 18 that the user does not have to perform calibration. It is of course provided that at least two calibration points 21 are marked on the holding device 15, via which the user after calling the calibration software the welding torch 3, in particular with a arranged on the welding torch 3 pin 22, positioned on the points and thus recalibrated.

In order to give the user the feeling of a real welding, the welding torch 3 is constructed by a torch handle 23, a pipe bend 24 and a hose package 25. The welding torch 3 has the same dimensions and the same weight as a real welding torch and is connected to the computer 2 via a line connection, in particular the hose package 25. Thus, the elements integrated with the welding torch 3 can be used by the user, as with a proper welding torch. Preferably, a start switch 26 for activating the simulated welding process is arranged on the burner handle 23. However, additional switching elements 27 for adjusting the predefinable welding parameters, such as wire feed, voltage, current, etc., may be arranged on the burner handle 23. Thus, the position of the welding torch 3 can be determined to the workpiece 4, the welding torch 3 is also connected to the positioning device 5, wherein in the pipe bend 24, in particular in the region of a burner tip, so the gas nozzle 20, the sensor 14 is arranged for determining the position. Here again it is essential that the sensor 14 is positioned as close as possible to the burner tip, so that the distance between the encoder 13 below the workpiece 4 and the sensor 14 in the welding torch 3 is as low as possible, so that the measurement accuracy is increased and external interference can be minimized. Between the encoder 13 and the sensor 13 in the welding torch 3, only the workpiece 4 and the wall thickness of the box 19 is arranged, whereby a very small distance between the encoder 13 and the sensor 14 in the welding torch 3 is present. Furthermore, a further sensor 14 can be arranged in the burner handle 23, so that a complete position evaluation of the welding torch 3 is made possible. An essential detail of the structure is that at the burner tip, so the gas nozzle 20, the pin 22 is arranged to simulate a welding wire, wherein the pin 22 is movably mounted in the burner tip, as shown by an arrow. Usually, a pin 22 is used in known constructions, which is fixedly integrated in the burner syringe. Due to the movable mounting of the pin 22 it is achieved that the user can bring the welding torch 3 up to the gas nozzle 20 to the workpiece 4, wherein the pin 22 is pressed into the welding torch 3, that is in the gas nozzle 20. This ensures that the user can no longer simply place this pin 22 on the workpiece 4 and guides the welding torch 3 over the pin 22, since when the pin 22 is placed on the workpiece 4 it is pressed into the welding torch 3. Thus, a particularly realistic simulation is possible because the welding torch 3 can be brought closer to the workpiece 4, as was previously the case. The protruding from the gas nozzle 20 pin 22 can also be made adjustable by the length of the protruding from the gas nozzle 20 pin 22 is adjustable, whereby differently long "stick-outs" can be trained. This can be done in a simple form such that at the gas nozzle 20, a small thumbwheel is arranged, via the length of the protruding pin 22 can be adjusted by turning. Of course, this adjustment can also be carried out automatically, for example by a small electric motor is integrated in the gas nozzle 20, over which the length of the protruding pin 22 is adjusted. An automatic adjustment of the "stick-out" length has the advantage that the user in the software can make a "stick-out" length adjustment, with subsequent automatic adjustment is made.

For an optimal simulation is further essential that the position of the eyes, in particular the eye angle of the user, to the workpiece 4 and the welding torch 3 is determined, for which the visualization device 16 is used. In the illustrated construction, two different visualization devices 16 can be used, in particular 3D glasses (not shown) and a novel design with a welding shield or a cap 28. On the use of 3D glasses is not discussed, since this is well known in the prior art.

However, since the 3D glasses has significant disadvantages, namely to be adapted to any visual weaknesses of a user, the novel visualization device 16 has been developed in which no adjustments are necessary. For this purpose, with the position monitoring device 5 and / or the computer 2, the visualization device 16, in particular a welding shield or a cap 28, connected to which a sensor 14 is arranged. In this case, the sensor 14 is preferably attached to a support frame of the welding shield or at the highest point of the cap 28, so that the sensor 14 is preferably located at the highest point when placing the user and thus the viewing angle of a user can be calculated. The user turns the welding screen or cap 28 upside down and can thus control the camera for visualizing the scene on the display device 6, in particular the screen 7, by moving the head. The screen 7 is preferably positioned so that it is placed directly behind the workpiece 4 or the box 19 so that the user can simultaneously view the workpiece 4 and the image 29 shown on the screen 7, since in this embodiment the visualization device 16 is the user only on the screen 7 the welding simulation gets displayed. The position of the camera is determined by a mounted on the welding helmet or the cap 28 Polhemus sensor and mounted in the workpiece 4 Polhemus encoder so that due to the movement of the user's head, the position of the Polhemus sensor is determined and a corresponding angle to Workpiece 4 and the welding torch 3 can be calculated, from which now a corresponding image 29 is generated on the screen. Of course, both a welding shield and a cap 28 can be used, whereby the user can choose with which type of visualization device 16 he wishes to perform the welding simulation.

The visualization device 16 is thus in the form of a Welding shield or a cap 28 is formed and arranged on a support frame of the visualization device 16, a sensor 14 of the position monitoring device 5. In the embodiment of the invention, the visualization device 16 is used as a camera with a special attenuation for the movement of the image 29, wherein at the beginning of the welding simulation, a target point of the visualization device 16 is statically in the middle of the workpiece 4 shown on the screen 7, and when approaching the Welding torch 3 to the workpiece 4, the target point dynamically changed at the respective penetration point of the extension of a burner axis and the workpiece 4, as shown schematically in the Figures 9 and 10 is shown. It is also in Fig. 10 It can be seen that the user has moved the welding torch 3 to the workpiece 4, since in the illustrated image now the welding torch 3, for reasons of clarity, appears only partially drawn in and the viewing angle has now changed dynamically. Such a visualization device 16 does not produce a virtual image in all directions in space, as with 3D glasses, but only an essential image section, namely the workpiece 4, is visible on the screen 7. At rest according to Fig. 9 only the area of the workpiece 4 is displayed, no matter in which direction the user looks with the attached visualization device 16. However, if the user moves the welding torch 3 into the display area, a virtual welding torch 3 becomes visible and a dynamic image display is switched over so that the position of the sensor 14 in the welding shield 3 and the cap 28 is determined and a corresponding view of the workpiece 4 is obtained the determined position is displayed. If the user moves the welding torch 3 back out of the display area, the position evaluation of the sensor 13 in the welding screen or cap 28 is so to speak deactivated and switched to the static image display. Thus, a simple mode was created in which no adjustment of visual impairments, as is necessary in 3D glasses, must be made and only the most essential is displayed on the screen 7.

The process of a virtual weld will not be discussed in more detail since these are the usual simulation software routines. The computer 2 has a corresponding software installed, determines the corresponding processes, calculated and makes appropriate representations of the individual elements on the screen 7 or in the 3D glasses. Only briefly mentioned that after the commissioning of the device 1, the user can make different settings on the computer 2 and at the same time can select the most different types of welding processes. Furthermore, it is possible for the user to additionally select whether or not to use aids such as control arrows for the correct position of the welding torch 3 when guiding the welding torch 3 along the workpiece 4. After the user has made all the settings and has opted for a visualization device 16, the user can bring the welding torch 3 into a starting position on the workpiece 4 and then start the virtual welding process. For this purpose, the user presses on the welding torch 3, the start switch 26, so that then the virtual arc between the workpiece 4 and the welding torch 3 is fired on the screen 7. Subsequently, the user guides the welding torch 3 with or without aids, such as distance arrows to the ideal position, along the workpiece 4, for which purpose a corresponding welding bead is formed on the screen 7 for the virtual image 29, which is calculated on the basis of the guidance of the welding torch 3. If the user has finished the welding process, in the illustrated solution the computer 3 now analyzes the welding process carried out and awards corresponding points via an integrated evaluation system. At the same time it is of course possible that the essential records, such as short circuits, etc., can be queried independently by the user.

In order to make the application as comfortable as possible for the user, several auxiliary modules, such as the user module described below for automatic recognition of the handedness (left-handed / right-handed) of the user, are integrated into the software as described with reference to FIG Figures 11 and 12 is shown. For this purpose, a recognition module for the automatic detection of the handedness of the user for the handling of the welding torch is used by software technology to control the simulation of the welding process. This recognition module is integrated in the software on the computer 2 and the user does not have to provide any information or settings regarding his handedness. In this case, the position between the burner handle 23 and gas nozzle 20 is determined and evaluated by the detection module with respect to the arranged in the holding device 15 workpiece 4 and it automatically the appropriate software for the simulation of the welding process, in particular the representation of the image 29 from the welding torch 3 is selected , In order to use such a detection module, it is necessary that at least two sensors 14 are arranged in the welding torch 3, wherein preferably a sensor 14 is installed in the gas nozzle 20 and a sensor 14 in the burner handle 23, as in Fig. 3 is apparent. Thus, it is possible that the position of the two sensors 14 with each other and with respect to the encoder 13 can be determined and depending on the position of the burner handle 23 left or right to the sensor 14 in the gas nozzle 20 can be determined, with which hand the user the welding torch 3 stops. For example, if the sensor 14 is disposed in the burner handle 23 to the left of the sensor 14 in the gas nozzle 20 with respect to the workpiece 4, the user holds the welding torch 3 with his left hand, as in Fig. 11 and the software activates the display on the screen 7 for a left-hander. If, however, the sensor 14 is arranged in the burner handle 23 to the right of the sensor 14 in the gas nozzle 20 and with respect to the workpiece 4, the welding torch 3 is held with the right hand, as in Fig. 12 and the software selects the representation of the welding torch 3 on the right-handed display screen 7.

Furthermore, an auxiliary module for improving the input friendliness is arranged, in which now the welding torch 3 additionally serves as input means. For this purpose, at least one defined area 30 of the holding device 15 is designed as an input module with stored functions, so that the functions deposited in these areas 30 can be selected and activated by positioning the welding torch 3 and activating the start switch 26 on the welding torch 3. Thus, for certain commands, the user no longer has to set the welding torch 3 out of his hand, but can make corresponding inputs directly with the welding torch 3. In this case, the defined area 30 is software-controlled via the position on the box 19 or the holding device 15 defined and preferably characterized by a simple sticker on the holding device 15. Thus, the user can position the welding torch 3 on this area 30 or these predetermined positions and then call and execute the function stored behind this position by actuating the start switch 26 arranged on the welding torch 3. Of course, a pointer element shown on the screen 7 can (not shown) by moving these positions or areas 30 on the holding device 15 are also moved to a corresponding position on the screen 7. Thus, there is also the possibility that either with a corresponding input device such as a mouse, the same function by the mouse or the welding torch 3 can be called. By using the welding torch 3, it is therefore possible to carry out a contactless selection of the region 30 or the position by simply determining the position of the welding torch 3. By touching the defined area 30, that is to say the sticker, a switching element connected to the pin 22 can also be activated with the simulated welding wire, thus the pin 22, by pushing in the pin 22 and the function stored for this area 30 can be selected and activated. Thus, the user no longer needs to operate the start switch 26 or another switching element 27, but only press more with the tip of the welding torch 3 on the corresponding area 30. To activate several possibilities, such as the contact with the pin 22 or the actuation of the switching element 27 and the start switch 26 on the torch handle 23 or connected to the computer 2 mouse, can be operated in parallel.

On the box 19 so certain defined areas 30 are arranged for input via the welding torch 3, whereby it is achieved that the user no longer has to put the welding torch 3 out of his hand to call certain functions or commands, whereby the user friendliness substantially increased becomes. A stored function for an area 30 may be, for example, start of the welding simulation, repetition of the welding simulation, or end of the welding simulation, etc. For example, the areas 30 may also be used for a confirmation button, a repeat button, a menu button, a back button, be designed so that with appropriate positioning and activation of the welding torch 3, a corresponding command on the computer 2 is executed.

In addition, a control module for selecting buttons or buttons shown on the output device 6 can be used, wherein none of the welding process simulation of this control module is activated, and the control of a pointer element, in particular a mouse pointer, by movement of the welding torch 3 in a certain area or area is performed. The control of the pointer element on the screen 7, which usually takes place with a mouse, can now be carried out via the welding torch 3, so that the user does not always have to change between the mouse and the welding torch 3. The user can perform all the functions of a mouse with the welding torch 3. For this purpose, a corresponding mouse pad can be used, on which a further encoder 13 is positioned. If the user guides the welding torch 3 onto the mouse pad, this is detected by the additional encoder 13 and the position of the welding torch 3 on the mouse pad is evaluated by the latter. The use of such a mouse pad has the advantage that no extensive position determinations are necessary, but this is limited to a certain size of the mouse pad and thus a guide of the pointer element is easily possible. It is essential that the software automatically detects whether a control of the pointer element or a welding process is performed. This can be done in a simple manner such that on the holding device 15 on the workpiece 4 certain start positions are set, so when you start the welding torch 3 to these start positions and when you activate the start switch 26 on the welding torch 3 simulation is started, while a control of the pointer element performed when the welding torch 3 is outside a predetermined distance to the starting position. Also, the automatic detection can be carried out such that always the closer position to the respective encoder 13 is evaluated on the holding device 15 or the mouse pad. In the Fig. 6 and 8th an embodiment for the simulation of a build-up welding in a fillet weld or a butt weld is shown. In principle, the build-up welding consists in that several layers of weld beads are arranged one above the other. For this purpose, it is provided that the first weld bead 31 is simulated or formed directly on the workpiece 4 to be used. That is, a workpiece 4 having a fillet weld or a butt weld without weld bead 31 therein, as in Figures 5 and 7 shown, which the user inserts first for the first weld and then exchanges the workpiece 4 after performing the first weld and through a workpiece 4 with a shown, simulated weld bead 31, according to FIG Fig. 6 and 8th , inserts and thus can perform the other welds. In the illustrated embodiment, the user only needs to turn over the workpiece 4 and insert it again into the holding device 15, since both embodiments are realized on a workpiece 4.

In Fig. 14 an embodiment of a welding torch 3 is shown in which the pin 22 or instead of the pin 22, a light source 32 is arranged. This light source 32 has the task of simulating the very bright arc of a real weld by activating the light source while performing a welding simulation at the start of the simulation and ignited at the same time on the display device 6 of the arc. For this purpose, a stroboscope light source 32 is preferably used. By simulating the arc at the welding torch 3 via the light source 32, the darkening of a protective visor on the welding helmet can also be simulated by using a welding screen as the visualization device 16 to darken the darkening screen on the welding screen by applying a voltage. This should be done synchronously with the activation of the light source 32. Of course, in an automatic darkening welding screen and a correspondingly bright light source, this can be done automatically and there is no need to control the computer 2 from. By using a light source 32 for the simulation of the arc, an even more realistic simulation of a welding process is achieved, since the user has a welding helmet should use and thus the poor visibility during welding can be trained.

The case 8 may also have an external interface (not shown) through which the case 8 can be connected to a real welding machine. The external interface is connected to the computer 2, so that data can be transmitted to the computer 2 from the welding device. Thus, for example, the user can download data from an in-use welder and then practice at home or in the office with these settings. Thus, simulations with actually used settings are possible, which can be dubbed in a simple form. For this purpose, the computer 2 arranged in the case 8 is designed as a laptop or the computer has an internal power supply, for example via batteries, it is possible that by activating the external interface on the case 8, the computer 2 automatically starts and starts up. Subsequently, the computer 2 automatically performs a data transmission so that the necessary data is downloaded from the connected welding machine. The user therefore only has to go with the case 8 to the welding device, connect the case 8 via the external interface with the welding device, whereupon the corresponding data is automatically transmitted.

Of course, data from the computer 2 in the case 8 can also be transmitted to the welding device. This is done when first welding tests are carried out via the welding simulation, which are then stored and then transferred to a welding machine.

A further possibility for improving the user-friendliness is achieved in that the workpieces 4 and the box 19 are equipped with an automatic recognition means, in particular an RFID chip and an RFID reader. In order for an automatic detection of the workpiece 4 used is made possible, whereby automatically a corresponding setting on the computer 2 is made. Thus, the user-friendliness of the system is significantly increased and sources of error in the setting can be minimized.

• Definition 1. Verfahren zur Erzeugung eines zweidimensionalen Bildes (29) an einer Ausgabevorrichtung (6) über eine Visualisierungsvorrichtung (16) für die Simulation eines Schweißprozesses durch einen Benutzer, bei dem an einem Computer (2) mit einer Eingabevorrichtung (11) und Ausgabevorrichtung (6) eine Positionsüberwachungsvorrichtung (5) mit zumindest einem Geber (13) und mehreren Sensoren (14), ein Schweißbrenner (3) verbunden wird und mit dem Schweißbrenner (3) eine an einem in einer Haltevorrichtung (15) angeordnetes simuliertes Werkstück (4) ein Schweißprozess simuliert wird, in dem die Position des Schweißbrenners (3) zum Werkstück (4) sowie die Position des Benutzers, insbesondere der Augen, über die Visualisierungsvorrichtung (16) erfasst wird und vom Computer (2) in ein an der Ausgabevorrichtung (6) erzeugtes Bild (29) umgewandelt wird, dadurch gekennzeichnet, dass die Visualisierungsvorrichtung (16) in Form eines Schweißschirms oder einer Kappe (28) für den Benutzer ausgebildet wird, und an der Visualisierungsvorrichtung (16) ein Sensor (14) der Positionsüberwachungsvorrichtung (5) angeordnet wird und dass die Visualisierungsvorrichtung (16) als Kamera mit einer speziellen Dämpfung für die Bewegung eingesetzt wird, wobei sich zu Beginn der Schweißsimulation ein Zielpunkt der Visualisierungsvorrichtung (16) statisch in der Mitte des Werkstückes (4) befindet, welcher Zielpunkt beim Annähern des Schweißbrenners (3) an das Werkstück (4) dynamisch am jeweiligen Durchdringungspunkt der Verlängerung einer Brennerachse und dem Werkstück (4) verändert wird.
• Definition 2. Verfahren zur Steuerung eines simulierten Schweißprozesses durch einen Benutzer, bei dem ein Computer (2) mit einer Eingabevorrichtung (11) und Ausgabevorrichtung (6), einem Schweißbrenner (3), einer magnetischen Positionsüberwachungsvorrichtung (5) an der zumindest ein Geber (13) und mehrere Sensoren (14) angeschlossen sind, wobei der Geber (13) an einer Haltevorrichtung (15) für ein simuliertes Werkstück (4) und zumindest an einer Visualisierungsvorrichtung (16) und dem Schweißbrenner (3) jeweils ein Sensor (14) positioniert werden, verbunden wird, dadurch gekennzeichnet, dass zumindest ein definierter Bereich (30) der als kleine, tragbare Box (19) zum Aufstellen auf einen Tisch (10) ausgebildeten Haltevorrichtung (15) als Eingabemodul mit hinterlegten Funktionen ausgebildet wird, und dass durch berührungslose Positionierung des Schweißbrenners (3) in der Nähe dieses zumindest einen definierten Bereichs (39) oder durch Berühren des zumindest einen definierten Bereichs (30) und durch Aktivierung eines Schaltelementes (26) am Schweißbrenner (3) und durch Ermittlung der Position des Schweißbrenners (3) über den Sensor (14) und den Geber (13) in der Box (19) die hinterlegten Funktionen ausgewählt und aktiviert werden.
• Definition 3. Verfahren nach Definition 2, dadurch gekennzeichnet, dass der zumindest eine definierte Bereich (30) softwaremäßig über die Position an der Box (19) definiert und bevorzugt durch einen einfachen Aufkleber an der Box (19) gekennzeichnet wird.
• Definition 4. Verfahren nach Definition 2 oder 3, dadurch gekennzeichnet, dass das Berühren des definierten Bereichs (30) mit einem Stift (22) zur Simulierung eines Schweißdrahts durchgeführt wird, wobei ein mit dem Stift (22) gekoppeltes Schaltelement aktiviert wird und die für diesen definierten Bereich (30) hinterlegte Funktion ausgewählt und aktiviert wird.
• Definition 5. Verfahren nach Definition 4, dadurch gekennzeichnet, dass die hinterlegte Funktion für den definierten Bereich (30) bevorzugt für den Start der Schweißsimulation oder Wiederholung der Schweißsimulation usw. ausgewählt werden.

Preferably, the present invention is defined as follows:

• Definition 1. A method for producing a two-dimensional image (29) on an output device (6) via a visualization device (16) for the simulation of a welding process by a user, comprising a computer (2) with an input device (11) and output device ( 6) a position monitoring device (5) with at least one encoder (13) and a plurality of sensors (14), a welding torch (3) is connected and with the welding torch (3) on a in a holding device (15) arranged simulated workpiece (4) a welding process is simulated, in which the position of the welding torch (3) to the workpiece (4) and the position of the user, in particular the eyes, via the visualization device (16) is detected and from the computer (2) in one of the output device (6 converted image (29), characterized in that the visualization device (16) in the form of a welding screen or a cap (28) for the B user is formed, and on the visualization device (16) a sensor (14) of the position monitoring device (5) is arranged and that the visualization device (16) is used as a camera with a special damping for the movement, wherein at the beginning of the welding simulation, a target point the visualization device (16) is located statically in the middle of the workpiece (4), which target point is dynamically changed at the respective penetration point of the extension of a burner axis and the workpiece (4) as the welding torch (3) approaches the workpiece (4).
• Definition 2. Method for controlling a simulated welding process by a user, comprising a computer (2) with an input device (11) and output device (6), a welding torch (3), a magnetic position monitoring device (5) on the at least one encoder ( 13) and a plurality of sensors (14) are connected, wherein the encoder (13) on a holding device (15) for a simulated workpiece (4) and at least on a visualization device (16) and the welding torch (3) each have a sensor (14) be positioned, is connected, characterized in that at least one defined Area (30) designed as a small, portable box (19) for installation on a table (10) holding device (15) is formed as an input module with stored functions, and that by contactless positioning of the welding torch (3) in the vicinity of this at least one defined area (39) or by touching the at least one defined area (30) and by activation of a switching element (26) on the welding torch (3) and by determining the position of the welding torch (3) via the sensor (14) and the encoder (13 ) in the box (19) the stored functions are selected and activated.
• Definition 3. Method according to definition 2, characterized in that the at least one defined region (30) is defined by software via the position on the box (19) and is preferably characterized by a simple sticker on the box (19).
• Definition 4. Method according to definition 2 or 3, characterized in that the touching of the defined area (30) is carried out with a pin (22) for simulating a welding wire, whereby a switching element coupled to the pin (22) is activated and for function defined in this defined area (30) is selected and activated.
• Definition 5. Method according to definition 4, characterized in that the stored function for the defined area (30) are preferably selected for the start of the welding simulation or repetition of the welding simulation etc.

Claims (4)

Method for controlling a simulated welding process by a user, comprising a computer (2) having an input device (11) and output device (6), a welding torch (3), a magnetic position monitoring device (5) on the at least one encoder (13) and a plurality of sensors (14) are connected, wherein the encoder (13) on a holding device (15) for a simulated workpiece (4) and at least on a visualization device (16) and the welding torch (3) are each a sensor (14) are positioned, is connected, characterized in that at least one defined area (30) as a small, portable box (19) for placement on a table (10) formed holding device (15) is formed as an input module with stored functions, and that by contactless positioning of Welding torch (3) in the vicinity of this at least one defined region (30) or by touching the at least one defined region (30) and by activating a switching element (26) on the welding torch (3) and by determining the position of the welding torch (3) via the sensor (14) and the encoder (13) in the box (19) the stored functions are selected and activated. A method according to claim 1, characterized in that the at least one defined region (30) defined by software on the position of the box (19) and is preferably characterized by a simple sticker on the box (19). A method according to claim 1 or 2, characterized in that the touching of the defined area (30) is performed with a pin (22) for simulating a welding wire, wherein a switching element coupled to the pin (22) is activated and the area defined for this (30) stored function is selected and activated. A method according to claim 3, characterized in that the stored function for the defined area (30) are preferably selected for the start of the welding simulation or repetition of the welding simulation, etc.

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